Wire Harness Insulation by Additive Manufacturing for Simpler Production
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Solution Overview
Problem
The production process of wire harnesses is complex and costly due to the need for conductor drawing, stranding, annealing, and extrusion molding of insulating layers, with additional steps required for cutting and stripping electrical wires.
Innovation Solution
A method involving additive manufacturing to form an insulator around pre-arranged wire harness conductors, eliminating the need for extrusion-molding of insulating layers and enabling integral insulation, suitable for large-batch and automatic production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional extrusion-molding process is used to produce insulating layers, then the wire harness can be produced with proper insulation, but the production process becomes complex and processing cost increases
Solution Approach 1:
The patent merges the insulation layer and the connector housing into a single integrated component. The insulating material is injected directly into the mold cavity where the conductors are positioned, forming an insulator that is structurally integrated with the connector housing, thereby eliminating the need for separate extrusion-molding processes and reducing production complexity
Solution Approach 2:
The connector housing serves multiple functions: it provides structural support, electrical insulation, and conductor positioning. By integrating the insulating function into the housing structure itself, the design reduces the number of separate components and processes needed, simplifying the overall production system
2Reliability
If traditional extrusion-molding process is used to produce insulating layers, then the wire harness can be produced with proper insulation, but the processing time increases
Solution Approach 1:
The conductors are pre-positioned and fixed in the mold cavity before the insulating material is injected. This preliminary arrangement of conductors allows the insulating layer to be formed in a single injection process without requiring separate steps for conductor positioning and insulation application, thereby reducing total processing time
Solution Approach 2:
The insulation formation is combined with the connector housing manufacturing into a single injection molding operation. The insulating material is injected directly into the mold cavity where it simultaneously forms the insulator and integrates with the housing structure, eliminating multiple sequential processing steps
3Ease of operation
If electrical wires are cut and stripped individually, then the wire harness can be assembled according to loop requirements, but the production efficiency decreases
Solution Approach 1:
The conductors are pre-cut to required lengths and pre-positioned in the mold cavity according to the specific loop requirements before injection molding. This preliminary preparation allows for customized wire harness configurations while maintaining high production efficiency through automated positioning and single-step insulation formation
Solution Approach 2:
The injection molding process automatically performs the functions of conductor positioning, insulation application, and connector formation in a single automated operation. The system self-adjusts to produce different wire harness configurations based on the conductor arrangement in the mold, eliminating manual cutting and stripping operations
4Ease of manufacture
If additive manufacturing is used to form insulator, then the production cost is reduced and efficiency improved, but the method must be suitable for large-batch automatic production
Solution Approach 1:
The patent replaces traditional mechanical extrusion-molding processes with injection molding technology. The injection molding process uses a delivery nozzle to inject molten insulating material directly into the mold cavity under pressure, forming the insulator in a single automated operation that is highly suitable for large-batch production and significantly reduces per-unit cost
Solution Approach 2:
The injection molding system automatically completes the entire insulation formation process without manual intervention. The delivery nozzle automatically injects material, the mold automatically forms the insulator around positioned conductors, and the cycle repeats continuously, enabling high-volume automatic production with consistent quality and low per-unit cost
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces production costs, improves efficiency, facilitates rapid production, and allows for easy mounting and connection to external appliances, while adapting to complex mounting environments.
Implementation Method 1
an insulator is formed by additive manufacturing to realize insulation and fixation
Data Source
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AI summary
The present disclosure provides a method for producing a wire harness, and a wire harness. The method for producing a wire harness includes: Step S10: arranging a plurality of wire harness conductors; and Step S20: forming an insulator by additive manufacturing, gaps being disposed between the wire harness conductors, and the insulator wrapping the wire harness conductors and being filled in the gaps. The present disclosure alleviates the technical problems of complex production process and high processing cost of wire harnesses.